Homebrew PCBs

if you need to still use the hole for a component leg i only know two 
methods.

the first method is thin walled copper tubes, filled with tin.

the tin holds them together but the copper is cut to small lengths already.
you insert such a cylinder in a hole and then kind of rivet it in.
the tin presses the copper aganst the hole walls.

when you have riveted the whole board you suck the tin out of the hole and
it should look like a throughhole-plated board.


the second method is using small rivets.
tiny hollow rivets are inserted into the (slightly bigger drilled) hole and 
either riveted in place or just soldered. the manufacturer claims even 
without soldering the riveting
action alone provides enough reliable contact.

the disadvantage of both methods is that it is realtively expensive.
i would try the rivets if i needed, but until now i could live without.


for the costs of the rivets i can easily make a board double the size, 
where it is then obviously no problem
to solder both sides.


In 99% of the cases i try to make single sided boards.
even in worst case (all smd) it should be possible to do it in less then 
double the area.

it is just a question of good part placement and good routing.
(sure with more complicated boards it is impossible but....)

st